Brake Caliper

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

Remove the caliper from the vehicle and place on a clean workbench.

CAUTION

NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

NOTE

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

The first method is as follows:

Stuff a shop towel or a block of wood into the caliper to catch the piston.

Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.

Fig. For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear

Fig. Withdraw the piston from the caliper bore

For the second method, you must rotate the piston to retract it from the caliper.

If equipped, remove the anti-rattle clip.

Fig. On some vehicles, you must remove the anti-rattle clip

Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.

Fig. Use a prytool to carefully pry around the edge of the boot . . .

Fig. . . . then remove the boot from the caliper housing, taking care not to score or damage the bore

Remove the piston seals from the groove in the caliper bore.

Fig. Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

Carefully loosen the brake bleeder valve cap and valve from the caliper housing.

Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.

Use crocus cloth to polish out light corrosion from the piston and bore.

Clean all parts with denatured alcohol and dry with compressed air.

To assemble:

Lubricate and install the bleeder valve and cap.

Install the new seals into the caliper bore grooves, making sure they are not twisted.

Lubricate the piston bore.

Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.

Use a suitable driving tool to seat the boots in the housing.

Fig. Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

Install the caliper in the vehicle.

Install the wheel and tire assembly, then carefully lower the vehicle.

Properly bleed the brake system.

Fig. There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

Removal & Installation

Disconnect the battery negative cable.

Raise the vehicle and support safely.

Remove the appropriate tire and wheel assemblies.

Loosen the parking brake cable adjustment from inside the vehicle.

Remove the retaining clips, and disconnect the parking brake cable from the rear brake caliper assembly.

NOTE

Do not let air into the master cylinder by allowing the reservoir to empty or complete system bleeding will be required.

On FWD models, to disconnect the brake hose from the caliper, remove the banjo bolt from the brake caliper.

On AWD models, hold the nut on the brake hose side and loosen the flared brake line nut. With the hose disconnected at the line, remove the brake hose from the caliper.

Remove the caliper lock pin. Pivot the caliper upward, and slide the caliper assembly from the caliper support.

To install:

On FWD models, install the rear brake hose onto the caliper with new washers in place and tighten the brake hose retainer.

On AWD models, connect the brake hose to the caliper and tighten the fitting to 9-12 ft. lbs. (13-17 Nm). Then connect the hose at the bracket to the steel line and tighten the fitting to 9-12 ft. lbs. (13-17 Nm).

NOTE

Do not twist the brake hose during installation.

Install the caliper over the brake pads, making sure stopper grove lines up with pad projection.

Fig. The brake caliper is mounted to the caliper support with two bolts

Fig. Remove the brake caliper-to- caliper support retaining bolts

Fig. Grasp the caliper and lift it from the caliper assembly from the caliper support

Fig. Loosen the caliper hose banjo bolt . . .

Fig. . . . then remove the bolt from the fitting

Fig. Make sure that you remove the copper washers and replace them with new ones during reassembly

Unlike most rear disc brake designs, this system does not incorporate the parking brake system into the rear brake caliper. Therefore, the rear brake system is serviced the same as the front system.

Raise the vehicle and support safely.

Remove the appropriate tire and wheel assembly.

NOTE

Do not allow the master cylinder reservoir to empty. An empty reservoir will allow air to enter the entire brake system and complete system bleeding will be required.

To disconnect the brake hose on models with a banjo-bolt connecting the brake hose to the caliper assembly, simply remove the bolt at the hose connection. To disconnect the brake hose on all other systems, hold the nut on the brake hose side and loosen the flared brake line nut.

CAUTION

Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

Once the hose has been disconnected from the line, remove the brake hose from the caliper.

Remove the caliper guide and lock pins and lift the caliper assembly from the caliper support.

To install

Position the caliper onto the caliper support.

Install the guide pin and lock pin. Tighten to 23 ft. lbs. (32 Nm).

Reconnect the brake hose or install the banjo bolt with new washers.

NOTE

Use caution not to twist the brake hose during installation.

Bleed the brake system.

WARNING

Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.

Apply brake pedal and inspect the system for leaks. Ensure proper operation and no leakage.